Embossed decorative boards

ABSTRACT

Embossed decorative boards ( 1 ) having a first and a second opposite edge ( 1   I  and  1   II  respectively) with a third and a fourth adjacent edge ( 1   III  and  1   Iv  respectively). The board ( 1 ) include an upper side decorative surface ( 2 ) an upper side embossing and a base layer. The embossing is comprised by surface structure areas ( 10 ) of which at least four are first and second outermost surface structure areas ( 10   L  and  10   R  respectively). The first outermost surface structure areas ( 10   L ) has each one end edge coinciding with the first edge ( 1   I ) of the board ( 1 ) while the second outermost surface structure areas ( 10   R ) has each one end edge coinciding with the second edge ( 1   II ). At least two surface structures having different visual characteristics is used, wherein two adjacent outermost surface structure areas ( 10   L  and  10   R  respectively) within the same board ( 1 ) has different surface structures. The first outermost surface structure areas ( 10   L ) of the first edge ( 1   I ) is numbered L I , L II , L III  etc. in a subsequent order starting from the third edge ( 1   III ) while the second outermost surface structure areas ( 10   R ) of the second edge ( 1   I ) is numbered R I , R II , R III  etc. The end edle of the outermost surface structure areas ( 10   L  and  10   R  respectively) with the same ordinal number of the first edge ( 1   I ) and the second edge ( 1   II ) has mainly the same length while of the surface structure is similar.

[0001] The present invention relates to decorative boards with a surfacestructure of the upper surface.

[0002] Products coated with thermosetting laminates are frequent today.They are foremost used where the demand for abrasion resistance is high,but also where resistance towards different chemicals and moisture isrequired. As an example of such products floors, floor beadings, tabletops, work tops and wall panels can be mentioned.

[0003] The thermosetting laminate mostly consists of a number of basesheets with a decor sheet placed closest to the surface. The decor sheetcan be provided with a desired decor or pattern. The most frequentpatterns usually represent the image of different kinds of wood, orminerals such as marble or granite. The surface of the laminate can beprovided with a structure during the laminating procedure which willmake the decor more realistic. Press plates with structure or structurefoils are frequently used when manufacturing such a laminate. A negativereproduction of the structure in the press plate or the foil will beimprinted into the laminate during the laminating procedure.

[0004] The structure suitably represents features characteristic for thepattern the decor represents in the laminate. The structure can be madecoarse to simulate for example roughly planed stone, or smooth withrandomly placed pits and micro cracks to simulate polished marble. Awood surface can for example be simulated by providing the surface withrandomly placed thin oblong indentations which imitate pores. Theseindentations must be oriented in the direction of the growth of thesimulated wood, which is indicated by the pattern of the grains, inorder to make the result realistic.

[0005] It has for a long time been a great need to be able tomanufacture a decorative thermosetting laminate with a decor patternwith a surface structure as life like as the decor reproduced.

[0006] According to the present invention the above mentioned needs havebeen met and a decorative board with a decorative surface with amatching surface structure that overlaps adjoining boards has beenachieved. The invention relates to embossed decorative boards having afirst and a second opposite edge with adjacent third and a fourth edges.The boards includes an upper side decorative surface, an upper sideembossing and a base layer. The invention is characterised in that theembossing is comprised by surface structure areas of which at least fourare first and second outermost surface structure areas. The firstoutermost surface structure areas has each one end edge coinciding withthe first edge of the board while the second outermost surface structureareas has each one end edge coinciding with the second edge. The secondedge is arranged opposite to the first edge. At least two surfacestructures having different visual characteristics is used, wherein twoadjacent outermost surface structure areas within the same board hasdifferent surface structures. The different surface structures can bearranged into surface structure groups after its visual characteristicswhereby the first outermost surface structure areas of the first edge isnumbered L^(I), L^(II), L^(III) etc. in a subsequent order starting fromthe third edge. The second outermost surface structure areas of thesecond edge is numbered R^(I), R^(II), R^(III) etc. in a subsequentorder starting from the third edge. The end edge of the outermostsurface structure areas with the same ordinal number of the first edgeand the second edge hereby has mainly the same length. The outermostsurface structure area with the same ordinal number of the first edgeand the second edge has a similar surface structure.

[0007] According to one embodiment of the invention the base layer mayconsist of a number of conventional dry base layer paper webs or baselayer paper sheets which are impregnated with a thermosetting resin. Theresin in the uppermost of these is preferably while the rest of the websor sheets for example may contain melamine-formaldehyde resin orphenol-formaldehyde resin. The decor paper web or decor paper sheetrespectively, is hereby placed on top of the conventional base layerwebs or base layer sheets after which the different paper webs or astack of sheets respectively are continuously or discontinuouslylaminated together at an elevated pressure and an elevated temperature.

[0008] The surface layer of the may suitably include a so called overlaypaper, placed on top of the decor paper. The overlay paper is suitablyimpregnated with melamine-formaldehyde resin. At least one of thethermosetting resin impregnated sheets, preferably the uppermost one ispreferably coated with hard particles, for example silica, aluminiumoxide and/or silicon carbide with an average size of 1-100 μm,preferably around 5-60 μm.

[0009] The overlay may alternatively be replaced by, or used togetherwith, a layer of ionomeric polymer where the polymer for example isconstituted of ethylene-methacrylateacid-copolymer while the ions forexample are constituted of sodium, zinc or lithium even though otherionomeric polymers are usable. It is also in this embodiment suitable toutilise hard particles as described above.

[0010] According to one embodiment of the invention the base layerconsists of a particle board or a fibre board. Such a base layer may be5-20 mm thick.

[0011] According to one embodiment of the invention the decor patternconsists of a number of sections of parallel rows of bars, where thebars in adjoining rows are mutually offset in the longitudinaldirection. The most popular decor used on floor boards is differentkinds of wood and minerals. The surface structures narrow indentationsin the surface of 0.1-10 mm width which simulates pores, cracks,graining, joints and knots. It is also possible to use micro structuresachieving matt or semi gloss surfaces. The latter can also be used incombination with the above.

[0012] According to one embodiment of the invention a demarcationconsisting of a 1-20 mm wide, preferably 3-10 mm wide, field without anysurface structure is used between adjacent structure areas.

[0013] According to an alternative embodiment of the invention ademarcation consisting of a 1-20 mm wide, preferably 3-10 mm wide, fieldwere one surface structure gradually transforms into another surfacestructure

[0014] The invention is further explained in connection to theaccompanying drawings showing different embodiments of the inventionwhere,

[0015]FIG. 1 shows schematically an embossed decorative board 1 in theform of a floor board according to an embodiment of the invention.

[0016]FIG. 2 shows schematically end parts of two embossed decorativeboards 1 according to an embodiment of the invention.

[0017]FIG. 3 shows schematically a rectangular embossed decorative board1 according to a second embodiment of the invention.

[0018]FIG. 4 shows schematically quadratic embossed decorative board 1according to a third embodiment of the invention.

[0019]FIG. 5 shows schematically a rectangular embossed decorative board1 according to a fourth embodiment of the invention.

[0020]FIG. 6 shows schematically a rectangular embossed decorative board1 according to a fifth embodiment of the invention.

[0021]FIG. 7 shows schematically a rectangular embossed decorative board1 according to a sixth embodiment of the invention.

[0022]FIG. 8 shows schematically parts of an embossed decorative board 1mainly corresponding to the embodiment shown in FIG. 1.

[0023]FIG. 9 shows schematically the embossing of an installed floorcovering according to an embodiment of the invention.

[0024] Accordingly, FIGS. 1 and 8 shows schematically an embosseddecorative board 1 in the form of a floor board having a first edge 1^(I) and a second opposite edge 1 ^(II) with a third and a fourthadjacent edge 1 ^(III) and 1 ^(IV) respectively. The board 1 include anupper side decorative surface 2, an upper side embossing and a baselayer. The embossing is comprised by a flat surface with recesses. Therecesses are in the drawing represented by black lines. The embossing iscomprised by surface structure areas 10 of which at least four are firstand second outermost surface structure areas 10 ^(L) and 10 ^(R)respectively. Only the outermost surface structure areas 10 ^(L) and 10^(R) respectively are for reasons of simplicity provided with structurerepresentation in the drawing. The first outermost surface structureareas 10 ^(L) has each one end edge coinciding with the first edge 1^(I) of the board 1 while the second outermost surface structure areas10 ^(R) has each one end edge coinciding with the second edge 1 ^(II).The second edge 1 ^(II) is arranged opposite to the first edge 1 ^(I).At least two surface structures having different visual characteristicsis used, wherein two adjacent outermost surface structure areas 10 ^(L)and 10 ^(R) respectively within the same board 1 has different surfacestructures. The different surface structures is arranged into surfacestructure groups after its visual characteristics whereby the firstoutermost surface structure areas 10 ^(L) of the first edge 1 ^(I) isnumbered L^(I), L^(II) and L^(III) in a subsequent order starting fromthe third edge 1 ^(III). The second outermost surface structure areas 10^(R) of the second edge 1 ^(I) is numbered R^(I), R^(II) and R^(III) ina subsequent order starting from the third edge 1 ^(III). The end edgeof the outermost surface structure areas 10 ^(L) and 10 ^(R)respectively with the same ordinal number of the first edge 1 ^(I) andthe second edge 1 ^(II) has mainly the same length A (see FIG. 8) whilethe outermost surface structure area 10 ^(L) and 10 ^(R) respectivelywith the same ordinal number of the first edge 1 ^(I) and the secondedge 1 ^(II) has a similar surface structure. Accordingly, as shown inFIG. 8, the length of ΔL^(I) is mainly the same as the length of ΔR^(I),the length of ΔL^(II) is mainly the same as the length of ΔR^(II) andthe length of ΔL^(III) is mainly the same as the length of ΔR^(III).

[0025]FIG. 2 shows schematically end parts of two embossed decorativeboards 1, in the form of a floor boards, before joining. The boards 1have a first edge 1 ^(I) and a second opposite edge 1 ^(II) with a thirdand a fourth adjacent edge 1 ^(III) and 1 ^(IV) respectively. The boards1 includes an upper side decorative surface 2, an upper side embossingand a base layer. The embossing is comprised by a flat surface withrecesses. The recesses are in the drawing represented by black lines.The embossing is comprised by surface structure areas 10 of which atleast four are first and second outermost surface structure areas 10^(L) and 10 ^(R) respectively. The first outermost surface structureareas 10 ^(L) has each one end edge coinciding with the first edge 1^(I) of the board 1 while the second outermost surface structure areas10 ^(R) has each one end edge coinciding with the second edge 1 ^(II).The second edge 1 ^(II) is arranged opposite to the first edge 1 ^(I).At least two surface structures having different visual characteristicsis used, wherein two adjacent outermost surface structure areas 10 ^(L)and 10 ^(R) respectively within the same board 1 has different surfacestructures. The different surface structures is arranged into surfacestructure groups after its visual characteristics whereby the firstoutermost surface structure areas 10 ^(L) of the first edge 1 ^(I) isnumbered L^(I), L^(II) and L^(III) in a subsequent order starting fromthe third edge 1 ^(III). The second outermost surface structure areas 10^(R) of the second edge 1 ^(I) is numbered R^(I), R^(II) and R^(III) ina subsequent order starting from the third edge 1 ^(III). The end edgeof the outermost surface structure areas 10 ^(L) and 10 ^(R)respectively with the same ordinal number of the first: edge 1 ^(I) andthe second edge 1 ^(II) has mainly the same length while the outermostsurface structure area 10 ^(L) and 10 ^(R) respectively with the sameordinal number of the first edge 1 ^(I) and the second edge 1 ^(II) hasa similar surface structure.

[0026]FIG. 3 shows schematically a rectangular embossed decorative board1 with short edge to long edge ratio of one to six. The embossing iscomprised by a flat surface with recesses. The recesses are in thedrawing represented by black lines. The embossing represents threelongitudinal rows of surface structure areas 10 where three differenttypes of surface structures is used. The board 1 shown in FIG. 3corresponds mainly with the embodiments shown in FIGS. 1 and 2 above.

[0027]FIG. 4 shows schematically quadratic embossed decorative board 1.The embossing is comprised by a flat surface with recesses. The recessesare in the drawing represented by black lines. The embossing representsthree longitudinal rows of surface structure areas 10 interrupted by anarrow diagonal bar. Four different types of surface structures is used.The board 1 shown in FIG. 3 corresponds mainly with the embodimentsshown in FIGS. 1, 2 and 3 above.

[0028]FIG. 5 shows schematically a rectangular embossed decorative board1 with short edge to long edge ratio of one to six. The embossing iscomprised by a flat surface with recesses. The recesses are in thedrawing represented by black lines. The embossing represents twolongitudinal rows of surface structure areas 10 where three differenttypes of surface structures is used. The different surface structures isarranged into surface structure groups after its grain direction wherebythe first outermost surface structure areas 10 ^(L) of the first edge 1^(I) is numbered L^(I) and L^(II) in a subsequent order starting fromthe third edge 1 ^(III). The second outermost surface structure areas 10^(R) of the second edge 1 ^(I) is numbered R^(I) and R^(II) in asubsequent order starting from the third edge 1 ^(III). The end edge ofthe outermost surface structure areas 10 ^(L) and 10 ^(R) respectivelywith the same ordinal number of the first edge 1 ^(I) and the secondedge 1 ^(II) has mainly the same length while the surface structure ofthe outermost surface structure area 10 ^(L) and 10 ^(R) respectivelywith the same ordinal number of the first edge 1 ^(I) and the secondedge 1 ^(II) has a similar surface structure.

[0029]FIG. 6 shows schematically a rectangular embossed decorative board1 with short edge to long edge ratio of one to six. The embossing iscomprised by a flat surface with recesses. The recesses are in thedrawing represented by black lines. The embossing represents threelongitudinal rows of surface structure areas 10 where three differenttypes of surface structures is used. The board 1 shown in FIG. 6corresponds mainly with the embodiments shown in FIGS. 1, 2 and 3 above.The middle row is however more narrow while the first and the third rowis wider.

[0030]FIG. 7 shows schematically a rectangular embossed decorative board1 with short edge to long edge ratio of one to six. The embossing iscomprised by a flat surface with recesses. The recesses are in thedrawing represented by black lines. The embossing represents rhomboidalsurface structure areas 10 where three different types of surfacestructures is used.

[0031]FIG. 8 is described together with FIG. 1 above.

[0032]FIG. 9 shows schematically the embossing of an installed floorcovering consisting of rectangular decorative boards 1 according to theinvention. The boards 1 used corresponds mainly with the embodimentshown in FIG. 3. The joints between the boards 1 are in the drawingillustrated by being drawn with heavier lines. The boards 1 have threelongitudinal row of surface structure areas 10 of which the outermostsurface structures 10 ^(L) and 10 ^(R) respectively are arranged so thata first row B^(I) of each board 1 ends with surface structure type I atboth short side ends while the second and the third row B^(II) andB^(III) respectively ends with surface structure type II and IIIrespectively. The intermediate surface structure areas 10 is arranged ina random order with the provision that two adjacent surface structureareas 10 of the same row is not of the same surface structure type.

[0033] The invention is not limited by the shown embodiments since theycan be varied in different ways within the scoop of the invention.

1. Embossed decorative boards (1) having a first and a second oppositeedge (1 ^(I) and 1 ^(II) respectively) with a third and a fourthadjacent edge (1 ^(III) and 1 ^(IV) respectively), which board (1)include an upper side decorative surface (2) an upper side embossing anda base layer, characterised in that the embossing is comprised bysurface structure areas (10) of which at least four are first and secondoutermost surface structure areas (10 ^(L) and 10 ^(R) respectively),the first outermost surface structure areas (10 ^(L)) each having oneend edge coinciding with the first edge (1 ^(I)) of the board (1) whilethe second outermost surface structure areas (10 ^(R)) has each one endedge coinciding with the second edge (1 ^(II)), being arranged oppositeto the first edge (1 ^(I)), that at least two surface structures havingdifferent visual characteristics is used, wherein two adjacent outermostsurface structure areas (10 ^(L) and 10 ^(R) respectively) within thesame board (1) has different surface structures, that the differentsurface structures can be arranged into surface structure groups afterits visual characteristics whereby the first outermost surface structureareas (10 ^(L)) of the first edge (1 ^(I)) is numbered L^(I), L^(II),L^(III) etc. in a subsequent order starting from the third edge (1^(III)) and that the second outermost surface structure areas (10 ^(R))of the second edge (1 ^(I)) is numbered R^(I), R^(II), R^(III) etc. in asubsequent order starting from the third edge (1 ^(III)) whereby the endedge of the outermost surface structure areas (10 ^(L) and 10 ^(R)respectively) with the same ordinal number of the first edge (1 ^(I))and the second edge (1 ^(II)) has mainly the same length while theoutermost surface structure area (10 ^(L) and 10 ^(R) respectively) withthe same ordinal number of the first edge (1 ^(I)) and the second edge(1 ^(II)) has a similar surface structure.
 2. Embossed decorative boards(1) according to claim 1 characterised in that the decorative surface(2) contains a number of conventional dry base layer paper webs or baselayer paper sheets which are impregnated with a thermosetting resinwherein the resin in the uppermost of these preferably ismelamine-formaldehyde resin while the rest of the webs or sheetspossibly contain melamine-formaldehyde resin or phenol-formaldehyderesin, wherein the decor paper web or decor paper sheet respectively, isplaced on top of the conventional base layer webs or base layer sheetsafter which the different paper webs or a stack of sheets respectivelyare continuously or discontinuously laminated together at an elevatedpressure and an elevated temperature.
 3. Embossed decorative boards (I)according to claim 1 characterised in that the base layer consists of aparticle board or a fibre board.
 4. Embossed decorative boards (1)according to claim 1 characterised in that the decor pattern consists ofa number of sections of parallel rows of bars, where the bars inadjoining rows are mutually offset in the longitudinal direction. 5.Embossed decorative boards (1) according to claim 1 characterised inthat a demarcation consisting of a 1-20 mm wide, preferably 3-10 mmwide, field without any surface structure is used between adjacentstructure areas.
 6. Embossed decorative boards (1) according to claim 1characterised in that a demarcation consisting of a 1-20 mm wide,preferably 3-10 mm wide, field were one surface structure graduallytransforms into another surface structure
 7. Embossed decorative boards(1) according to any of the claims 1-7 characterised in that the surfacelayer of the laminate includes a so called overlay paper, placed on topof the decor paper.
 8. Embossed decorative boards (1) according to claim7 characterised in that the overlay paper is impregnated withmelamine-formaldehyde resin.
 9. Embossed decorative boards (1) accordingto any of the claims 2 or 7 characterised in that at least one of thethermosetting resin impregnated sheets, preferably the uppermost one iscoated with hard particles, for example silica, aluminium oxide and/orsilicon carbide with an average size of 1-100 μm, preferably around 5-60μm.
 10. Embossed decorative boards (1) according to claim 1characterised in that the upper side decorative surface is constitutedof a decorative layer and a ionomeric polymer.
 11. Embossed decorativeboards (1) according to claim 1 characterised in that the upper sidedecorative surface is constituted of a decorative layer, a ionomericpolymer and hard particles.
 12. Embossed decorative boards (1) accordingto claim 1 characterised in that the upper side decorative surface isconstituted of a decorative layer, a ionomeric polymer, overlay paper,impregnated with melamine formaldehyde and hard particles.
 13. Embosseddecorative boards (1) according to any of the claims 9-12 characterisedin that the decorative layer is made of paper.